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AZBMW Forums › Model Specific Discussion › 1-4 Series › E46 330 to M3 rear end swap
E46 330 to M3 rear end swap
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bullfrog
WorldTouringChamp
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PostPosted: Tue Nov 25, 2014 2:47 pm
Post subject: E46 330 to M3 rear end swap

This thread is to chronicle my swapping of an E46 M3 rear end into my ZHP, (hopefully) not having to go to a garage for anything, just elbow grease and my own garage.

Why? To give the car an LSD so the forced induction system that was installed can put the power down properly
Where? Complete swap should be accomplished all in house, in the garage
How much? Depends.... See details below
Swear words thrown? 6 so far and counting.......
Mindset? yea, still in flux. Key thing to remember though!!!! You are buying parts for an M3, NOT a regular E46, this is critically important as a lot of parts are NOT interchangeable nor are they as cheap as a non-m3 Sad

Costs? (will update as I build it up and buy parts)
Complete Rear End - $700
Bushing Refresh Kit - $600
CV Boots (inner and outer - 2x) - $175
Tool Rental (Koch rear bushing tool- rented from e46fanatics user) - $100
36MM 12Point Socket - $10
Rear Wheel Bearing (2x) - $80
Rear Wheel Bearing Lock Ring (2x) - $6
Rear Wheel Bearing Hub Nut (2x) - $24
CV boot crimp tool - $9
Various chemicals (Degreaser, Anti-Seize, etc..) - $40 and climbing slowly

Starting Part list:
2002 E46 M3 Complete rear end with 144K miles on it. Contains everything minus E-brakes, rotors and pads

Swapped in part list:
Complete Rear End Bushing Refresh kit - www.ecstuning.com/ES2500766/
Inner CV Boots (2x) - www.ecstuning.com/ES258448/
Outer CV Boots (2x) - www.ecstuning.com/ES57063/
Redline CV2 Grease for CV rebuilds
Emergency Brake build - (still sourcing all the parts from ECS - but about $100 for both sides combined)
Rotors and Pads - (haven't ordered or sourced them yet)
Differential Oil - www.ecstuning.com/ES197413/
Rear Driveshaft - (haven't sourced it yet but bmrparts.com has some rebuilt for about $300 shipped)
Rear Wheel Bearing (2x) - Autohausaz
Rear Wheel Bearing Lock Ring (2x) - Autohausaz
Rear Wheel Bearing Hub Nut (2x) - Autohausaz

Helpful Links:
DIY CV Boot Replacements - www.m3forum.net/m3foru...p?t=306997
DIY Rear end replacement - www.m3forum.net/m3foru...p?t=464146

Complete Rear End before teardown (I put it on three furniture dollies to make it easy to move around and breakdown - Lifesaver right there, if you do this project, DO THIS!! $11/each at harbor freight)


First thing a lot of people are going to say.... "Why are you replacing all of the bushings like that"?
1. The rear end came out of Colorado, i.e.: Snow, Salt, rust..... Due to this, there were a significant amount of seized bolts and seriously scary looking bushings, due to rust, not bad deep rust, just surface rust.
2. At 145K miles, I don't know when the last time ANY of the bushings were replaced. I want what is essentially a brand new rear end that will make it another 100K miles (or as close to that as possible)
3. More of point 2, I don't want to have to get under the rear end again in 40-50K miles to replace a bushing that I could of done during the tear down and reassembly
4. I don't want to get POLY on any of it. I want a nice OEM ride quality coming out of the rear end. A lot of people say i should of gotten poly on a lot of the bushings, but I don't want a stiff ride. I want something that will ride nice but still respond well since i am not an aggressive driver. OEM and ECS upgraded bushings will meet those requirements.


Tear down pics:

Carrier, wishbones, sway bar and trailing arms removed


Halfshafts (or are they called axles? Whatever, i call em half shafts) removed from diff


Removing the wheel hubs from the wheel bearings and half shafts


I really don't swing that way BMW but.....okay :/ AND it's going in my rear end? ..............no comment


Wheel hub pulled off the wheel bearing races along with it. This is where I might have to have a garage come into play. I cannot for the life of me get this race off of the hub and new hubs cost $100/each!!!!!!!!! I really REALLY don't want to have to buy brand new wheel hubs


Starting to tear into the CV Boots to replace them. The amount of grease in these things is astronomical. I mean, these things are packed with massive amounts of grease.


A pile of rear end parts waiting for me to get to them to wire brush, clean up and respray with a good couple coats of rust protection and paint. Should I do a candy cane paint job on my half shafts? lol

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xAZxE30x
Mr. Unicorn

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PostPosted: Wed Nov 26, 2014 3:25 pm
Post subject: Re: E46 330 to M3 rear end swap

Good work man!! This will kick ass!

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ccc13
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PostPosted: Wed Nov 26, 2014 5:13 pm
Post subject: Re: E46 330 to M3 rear end swap

I <3 your ZHP, and this makes me just a bit more jealous. Looks like fun!
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e46tuner
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PostPosted: Thu Nov 27, 2014 2:00 am
Post subject: Re: E46 330 to M3 rear end swap

Nice DIY project. Glad to see your thoroughly inspecting everything.

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giantkeeper
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PostPosted: Thu Nov 27, 2014 1:02 pm
Post subject: Re: E46 330 to M3 rear end swap

J, I'll grab that press tomorrow and we can pop those races free. I need it for some projects here anyhow.

Btw, awesome project! I can't wait for the next phase....

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2002 SG E46 M3
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xAZxE30x
Mr. Unicorn

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PostPosted: Thu Nov 27, 2014 1:31 pm
Post subject: Re: E46 330 to M3 rear end swap

Black Friday deal on a press?

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Mtrace
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PostPosted: Thu Nov 27, 2014 5:08 pm
Post subject: Re: E46 330 to M3 rear end swap

I put a small cut in my races and them smacked them with a center punch, they are hard and brittle, the cut creates a stress fracture and they break right off....if the press doesn't work

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giantkeeper
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PostPosted: Sun Nov 30, 2014 11:18 pm
Post subject: Re: E46 330 to M3 rear end swap

Mtrace wrote:
I put a small cut in my races and them smacked them with a center punch, they are hard and brittle, the cut creates a stress fracture and they break right off....if the press doesn't work

Cut with a Dremel and smacked them a few times. Worked like a charm. Incidentally, so does my press. I'm not sure how I have waited so long to buy one.

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2002 SG E46 M3
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bullfrog
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PostPosted: Sun Nov 30, 2014 11:46 pm
Post subject: Re: E46 330 to M3 rear end swap

Bushings pulled out of the rear subframe carrier


Rebuilding the inner cv boot, cleaning up the old bearings and gear assembly and then repacking with Redline CV2 grease


Chris got the wheel bearing race off the hub. Scored it with the dremel and then banged on it a little bit until the score "broke" the race and started to spin free


Both of the wheel hubs cleaned up with the wire wheels and some degreaser. You can see where we slightly scored the hub when trying to dremel off the race. Not too worried about it, since it is a very small surface score and the wheel bearing will completely cover it up anyway. (Thanks again for the help Chris!!!)


Cleaned up the calipers and caliper brackets with a wire wheel....little bit of the ///M coming through. Might have to do a tri color setup on the M "hashes" (what are they even called anyway?) when I do the painting.

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